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How Toyota's 100-year textile history influenced FCV hydrogen fuel cell car

Turns out, Toyota had a surprising ace in the hole when it came to building the new fuel tanks for the FCV hydrogen fuel cell car, which is coming next year. Well before Toyota became the Toyota Motor Company, it was the Toyota Industries Corporation and it made textile looms. This is important because the main structure of the hydrogen tank is wound carbon fiber. When Toyota set out to increase the strength of the tanks to hold hydrogen stored at 10,000 psi (up from 5,000 in the previous tanks), it was able to draw on its 100-year-old history as it designed its car of the future. "A lot of that textile experience came back when we did the tank wrapping." – Justin Ward "We have a lot of experience with textiles," Justin Ward told AutoblogGreen at the 21st World Congress on Intelligent Transport Systems (ITS) in Detroit this week, "and a lot of that textile experience came back when we did the tank wrapping." On top of being able to hold the higher-pressure hydrogen, Toyota's first attempt to build its own hydrogen tank was six times faster than the industry standard, so it saved time and money as well as working better. The company will also be able to inspect its own tanks. Ward is the general manager of powertrain system control at the Toyota Technical Center and hydrogen vehicles are something he knows a lot about. The reason for the stronger, 10,000-psi tanks is because the 5,000-psi tanks only offered around 180-200 miles of range, even with four tanks in the early $129,000 FCHV Highlander hydrogen prototypes. The FCV only has two, but they will able to deliver the 300-mile range that customers told Toyota they wanted. Dropping the number of tanks not only obviously reduced the cost for the tanks themselves but also the number of valves and hoses and other components you need. Despite the benefits of higher compression, going much higher doesn't make sense. 10,000 psi is the "natural progression," Ward said, because "you start to bump up against compression inefficiencies." Think of an air compressor. When hydrogen is produced at a wastewater treatment plant or a reforming site, Ward said, is it at around ambient pressure (14 psi). That has to be raised, using compressors, all the way to 10,000 psi. "That takes energy," Ward said, "and every doubling of pressure adds another doubling of energy needed, so it starts to add up pretty fast if you go too high." Component specifications are also fine at 10,00 psi, but more difficult at higher levels.

GM, Ford, Honda winners in 'Car Wars' study as industry growth continues

General Motors' plans to aggressively refresh its product lineup will pay off in the next four years with strong market share and sales, according to an influential report released Tuesday. Ford, Honda, and FCA are all poised to show similar gains as the auto industry is expected to remain healthy through the rest of the decade. The Bank of America Merrill Lynch study, called Car Wars, analyzes automakers' future product plans for the next four model years. By 2020, 88 percent of GM's sales will come from newly launched products, which puts it slightly ahead of Ford's 86-percent estimate. Honda (85 percent) and FCA (84 percent) follow. The industry average is 81 percent. Toyota checks in just below the industry average at 79 percent, with Nissan trailing at 76 percent. Car Wars' premise is: automakers that continually launch new products are in a better position to grow sales and market share, while companies that roll out lightly updated models are vulnerable to shifting consumer tastes. Though Detroit and Honda grade out well in the study, many major automakers are clumped together, which means large market-share swings are less likely in the coming years. Bank of America Merrill Lynch predicts the industry will top out with 20 million sales in 2018 and then taper off, perhaps as much as 30 percent by 2026. Not surprisingly, trucks, sport utility vehicles and crossovers will be the key battlefield in the next few years, Car Wars says. FCA will launch a critical salvo in 2018 with a new Ram 1500, followed by new generations of the Chevy Silverado and GMC Sierra in 2019, and then Ford's F-150 for 2020, according to the study. Bank of America Merrill Lynch analyst John Murphy said the GM trucks could be pulled ahead even earlier to 2018, prompting Ford to respond. "This focus on crossovers and trucks is a great thing for the industry," Murphy said. Cars Wars looks at Korean (76 percent replacement rate) and European companies more vaguely (70 percent), but argues their slower product cadence and lineups with fewer trucks puts them in weaker positions than their competitors through 2020. Related Video: This content is hosted by a third party. To view it, please update your privacy preferences. Manage Settings. Featured Gallery 2016 Chevrolet Silverado View 11 Photos Image Credit: Chevrolet Earnings/Financials Chrysler Fiat Ford GM Honda Nissan Toyota study FCA

Recharge Wrap-up: First EV to attempt Dakar Rally, Mazda makes bioplastic parts

Zap and Jonway Auto brought their Urbee EV and their new Falcon A-380 SUV to the Peru Motor Show in Lima. Jonway sells its SUV and minivan in Lima through Dai-Ichi Motors, which displayed the cars at the show. According to the companies, their cars "received tremendous interest from the public," including private citizens as well as groups who would use the EVs for security guard service or campus use. Read more in the press release below. California is the US leader when it comes to EVs. In 2013, California had 70,000 battery electric and 104,000 plug-in hybrids. The state boasts almost half of the country's electric vehicles, thanks largely to state and local EV incentives that go beyond the federal tax rebate. California also leads the way in legislation, and nine other states have adopted California's ZEV mandate. Washington, Maryland, Georgia and DC also have their own EV incentives, while some utility companies also offer benefits for EV owners in other states. Still, EV sales have only made up about 0.7 percent of new vehicle sales in 2014. Read more at the US Energy Information Administration website. Toyota will be using landfill gas to help power its Kentucky manufacturing facility. Beginning in 2015, Toyota's Georgetown assembly plant will use electricity converted from landfill-sourced methane gas from Waste Services of the Bluegrass. It will provide enough energy to produce 10,000 vehicles each year. Plus it diverts methane - a greenhouse gas - from entering the atmosphere and helps improve the local air quality. Learn more in the video or Toyota's press release below. Mazda has developed a plant-derived bioplastic for making exterior and interior parts. The dyed plastic doesn't require painting, and it reduces petroleum consumption and carbon emissions in the manufacturing process. The bioplastic will be used for interior parts in the all-new MX-5 before being put into use on the exterior of future vehicles. Mazda will display prototype parts at the Eco-Products 2014 exhibit in Tokyo. Read more in the press release below. Acciona will enter the first-ever zero-emissions vehicle (pictured) to compete in the Dakar Rally. The vehicle uses an electric motor and lithium ion batteries, as well as solar panels to power telemetry and security systems. The Dakar Rally will take place from January 4 through 17 through Argentina, Chile and Bolivia. See Acciona's Dakar EV in the video and read more in the press release below.